Lactone modified adducts or reactants and oleaginous compositions containing same

ABSTRACT

C 5  -C 9  lactone based adduct materials are made by reacting a C 5  -C 9  lactone with a polyamine, a polyol or an amino alcohol to form a lactone adduct intermediate, and thereafter reacting the intermediate with a hydrocarbyl substituted C 4  -C 10  monounsaturated dicarboxylic acid producing material, e.g., a polyisobutenyl succinimide, which, in turn, preferably was made by reacting a polymer of a C 2  to C 10  monoolefin, preferably polyisobutylene, having a molecular weight of about 300 to 10,000 with a C 4  to C 10  monounsaturated acid, anhydride or ester, preferably maleic anhydride, such that there are 0.7 to 2.0 dicarboxylic acid producing moieties per molecule of said olefin polymer used in the reaction mixture. The resulting adduct material are useful per se, as oil soluble dispersant additives, and are useful in fuel and lubricating oil compositions including concentrates containing the additives.

RELATED U.S. APPLICATIONS

This application is related to the following applications filed by the inventors herein: Serial No. 916,218, Serial No. 916,114, Serial No. 916,287, Serial No. 916,108, Serial No. 916,303 and Serial No. 916,217. All of the above applications were filed on even date herewith. All of these related applications are expressly incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to oil soluble dispersant additives useful in fuel and lubricating oil compositions, including concentrates containing said additives, and methods for their manufacture and use. The dispersant additives are poly (C₅ -C₉ lactone) adducts which have been prepared by first reacting a C₅ -C₉ lactone with a polyamine, a polyol or an amino alcohol to form an intermediate adduct, whereafter the intermediate adduct is reacted with a dicarboxylic acid, anhydride ester, etc., which in turn has been substituted with a high molecular weight hydrocarbon group. The high molecular weight hydrocarbon group has a number average molecular weight (M_(n)) of about 300 to about 10,000. The additives will have a ratio (functionality) of about 0.70 to about 2.0 dicarboxylic acid producing moieties for each equivalent weight of the high molecular weight hydrocarbon therein.

2. PRIOR ART

Polyalkylene substituted C₄ -C₁₀ dicarboxylic acid and anhydride adducts with polyols and polyamines are well known lubricating additives. These agents act to keep sludge and varnish dispersed in engine oils and have been very successful commercially.

It is also known that polymers of 6 to 9 membered lactones such as valerolactone or epsiloncaprolactone (hereinafter caprolactone or E-caprolactone), can be prepared by reacting the lactone monomer with a hydoxyl or amine initiator. When reacting E-caprolactone, for example, the polymerication reaction may be illustrated by the following equations: ##STR1##

The reactions are known to be catalyzed by various esterification catalysts such as stannous octanoate, and a variety of different molecular weight products are feasible depending upon the ratio of lactone to initiator. Molecular weights on the order of form a few hundred up to about 5000 are reproducably achievable.

Caprolactone can also be polymerized to a very high molecular weight, e.g., on the order of 100,000 or more. Typically such high molecular weight polymers do not employ initiators and preservation of functionality is not a requirement.

It is also known to react a lactone such as E-caprolactone with a polyol to form polyesters having terminal hydroxyl groups which are useful as plasticizers.

It has now been found that improved oil soluble dispersant additives, useful in fuel and lubricating oil compositions, including concentrates containing the additives, can be prepared by first reacting a 6 to 10 membered lactone with either a polyamine, a polyol or an amine alcohol to form an intermediate adduct, and then reacting the intermediate adduct with a known class of oil soluble dispersants, namely: dicarboxylic acids, anhydrides, esters, etc. that have been substituted with a high molecular weight hydrocarbon group. A typical example of one such known oil soluble dispersant is a polyalkylene succinic anhydride, wherein the polyalkylene moiety has a number average molecular weight of about 300 to about 10,000 and wherein the ratio (functionality) of succinic acid producing moieties to each equivalent weight of the polyalkylene moiety is from about 0.70 to about 2.0.

While there are a number of prior art disclosures relating to adducts of lactones and polyols and/or amino alcohols to polyalkenyl succinic acid or anhydride type dispersants, and to lactone polymerization reactions, in general, little or no prior art of direct pertinence appears to have surfaced in regard to the present dispersants. Exemplary of the patent literature which relates to lactone polymerization processes and/or to oil soluble dispersant additives are the following U.S. Patents: U.S. Pat. No. 4,362,635 discloses synthetic ester oils which are esterification products of monoalcohols and dicarboxylic acids or of polyhydric alcohols and monocarboxylic acids respectively, containing 5 to 45% by weight of units of hydroxycarboxylic acids obtained from aliphatic alcohols, aliphatic, cycloaliphatic or aromatic carboxylic acids, and lactones of aliphatic C₅ -C₁₂ hydrocarboxylic acids. The synthetic ester oils are suitable for the preparation of lubricants and lubricant compositions.

U.S. Pat. No. 2,890,208 discloses a process for polymerizing lactones to form lactone polyesters that are useful as plasticizers.

U.S. Pat. No. 3,950,341 relates to oil soluble detergent dispersants which are prepared by reacting a polyalkenyl succinic acid or its anhydride with a hindered alcohol such as pentaerythritol, and then with an amine.

U.S. Pat. No. 4,062,786 and its continuation-in-part (U.S. Pat. No. 4,292,184) disclose lactone oxazoline reaction products of hydrocarbon substituted lactone carboxylic acids such as polybutyl lactone carboxylic acid, with a 2,2-disubstituted-2-amino-1-alkanol such as tris-(hydroxymethyl)amino-methane (THAM). The reaction products and their derivatives are disclosed as being useful additives in oleaginous compositions such as sludge dispersants for lubricating oil.

U.S. Pat. No. 4,169,836 discloses reacting hydrocarbon substituted dicarboxylic acids, esters, or anhydrides, for example, octadecenylsuccinic anhydride and polyisobutenyl succinic anhydride with 2,2-disubstituted-2-amino-1-alkanols, for example, THAM, to form oxazoline products which are useful as additives in oleaginous compositions, such as sludge dispersants for lubricating oil.

U.S. Pat. No. 4,234,435 discloses as oil additives, polyalkylene substituted dicarboxylic acids derived from poly-alkylenes having a M_(n) of 1300 to 5,000 and containing at least 1.3 dicarboxylic acid groups per polyalkylene. In Example 34 of that patent, a polyisobutene-substituted succinic acylating agent is reacted with caprolactam in the presence of mineral oil and sodium hydroxide.

U.S. Pat. No. 3,381,022 relates to ester derivatives of substantially saturated polymerized olefin-substituted succinic acid wherein the polymerized olefin substituent contains at least about 50 aliphatic carbon atoms and has a molecular weight of about 700 to 5,000. The esters include the acidic esters, diesters, and metal salt esters wherein the ester moiety is derived from monohydric and polyhydric alcohols, phenols and naphthols. The ester derivatives are useful as additives in lubricating compositions, fuels, hydrocarbon oils and power transmission fluids. A related application, i.e., U.S. Pat. No. 3,522,179, relates to lubricating compositions comprising a major amount of a lubricating oil and a minor proportion of an ester derivative of a hydrocarbon-substituted succinic acid sufficient to improve the detergency of the lubricating composition. The ester derivatives are similar to those described in U.S. Pat. No. 3,381,022 and contain at least about 50 aliphatic carbon atoms. The hydrocarbon substituent may be derived from a polymerized lower monoolefin having a molecular weight of from about 700 to about 5,000.

U.S. Pat. No. 4,379,914 and its continuation-in-part (U.S. Pat. No. 4,463,168) disclose the preparation of polycaprolactone polymers by reacting E-caprolactone with a diamine wherein one of the amine groups of the diamine is a tertiary amine and the other is a primary or secondary amine. The polycaprolactone polymers are disclosed as being useful for neutralizing certain sulfonic acid-containing polymers to form amine-neutralized, sulfonated derivatives which can be combined with an alkyl benzene sulfonic acid to give a surfactant which contains ester groups, hydroxyl groups and amine-neutralized sulfonate groups.

U.S. Pat. No. 3,169,945 discloses the preparation of lactone polyesters which are useful as plasticizers and as intermediates for preparing elastomers and foams. The polyesters can be prepared by reacting a lactone such a E-caprolactone with an initiator such as an alcohol, amine or amino alcohol. A similar disclosure is contained in U.S. Pat. No. 3,284,417.

U.S. Pat. No. 3,025,323 relates to a class of diols which are derived through the action of omega-lactones on the primary amine groups of monoalkanolamines and on the amine groups of primary diamines. The compounds disclosed in this patent are useful as intermediates in the synthesis of polymers and as softeners and sizes for paper, leather and other porous materials.

U.S. Pat. No. 3,436,463 discloses N-substituted-gamma hydroxycarboxylic acid amides which are useful as nematocide and insecticides. The compounds of this patent are prepared by reacting an organic primary amine with a lactone such as gamma-butyrolactone or gamma-valerolactone.

U.S. Pat. No. 4,532,058 discloses as a motor oil dispersant, a spirodilactone condensation product formed by heating alkenyl succinic anhydrides in the presence of a basic catalyst, and then heating the resulting bicyclic spirodilactone condensation product with a polyamine or polyamine alcohol. It should be emphasized that this patent describes the intermolecular decarboxylation of an alkenyl succinic anhydride at elevated temperatures to form a condensation product and carbon dioxide as a byproduct. This prior art is not concerned with polymerizable lactones which are the subject of the instant invention.

U.S. Pat. No. 3,448,049 relates to lubricating oil additives based on polyolefinic succinate derivatives which are prepared by reacting an alkenyl succinic anhydride or an alkenyl succinic anhydride derivative with at least one hydroxy compound which also contains amide groups.

U.S. Pat. No. 2,638,449 discloses lubricating oil additives derived from alkenyl succinic anhydride esters of hydroxy compounds containing fatty acid amide groups.

U.S. Pat. No. 4,540,809 discloses acrylate esters of dipentaerythritol caprolactone condensates. The esters are useful as vehicles for paints and can be hardened by ionizing radiation or thermal means.

U.S. Pat. No. 4,086,294 discloses water soluble polycaprolactone-epoxide adducts which are produced by reacting a polycaprolactone polyol, a diepoxide and an anhydride of a polycarboxylic acid, such as substituted or unsubstituted succinic anhydride. The polycaprolactone-epoxide adducts are useful in the preparation of aqueous coating compositions. Similar polycaprolactone-epoxide adducts are disclosed in U.S. Pat. No. 4,261,871.

U.S. Pat. No. 3,438,943 relates to polyesters which are derived from oxazoline polyols and which are useful in water-thinned paints. The oxazoline polyols are prepared by reacting an acid or acid derivative and a polyhydroxyamine such as THAM.

U.S. Pat. No. 4,397,750 teaches the preparation of hydroxy substituted pyrrolidone esters from butyrolactones and polyhydroxyamines. Corresponding hydroxyamide side-products are also disclosed. The disclosed esters are useful as additives for lubricants and fuels.

U.S. Pat. No. 4,247,671 discloses the preparation of oxazoline alcohols via the condensation of, for example, caprolactone with an appropriate amine, for example, 2-amino-2-methyl-1-propanol. The oxazoline alcohols can be used to prepare oxazoline-containing polymer coatings. Analogous adducts prepared from butyrolactone and monohydroxy amino alcohols are disclosed in U.S. Pat. No. 4,448,905.

U.S. Pat. No. 3,493,568 discloses diol amides prepared from caprolactone and a monohydroxy amino alcohol. The diol amides can be cyclodehydrated to form oxazolines and oxazines which can be polymerized to yield crosslinked polymeric structures.

U.S. Pat. No. 4,017,406 discloses ester derivatives of long chain dicarboxylic anhydrides such as octadecenyl and polyisobutenylsuccinic anhydrides and aldehyde/THAM adducts for use as additives for oleaginous compositions.

All of the above discussed patents are expressly incorporated herein by reference in their entirety.

Additional exemplary prior art disclosures, which are expressly incorporated herein by reference in their entirety are U.S. Pat. Nos. 2,290,154; 2,568,619; 2,767,144; 3,062,631; 3,087,936; 3,131,150; 3,154,560; 3,172,892; 3,198,736; 3,202,678; 3,215,707; 3,219,666; 3,231,587; 3,325,484; 3,269,946; 3,272,743; 3,272,746; 3,278,550; 3,284,409; 3,284,417; 3,288,714; 3,361,673; 3,367,895; 3,379,693; 3,390,086; 3,401,118; 3,403,102; 3,455,827; 3,562,159; 3,576,743; 3,632,510; 3,699,165; 3,684,771; 3,708,522; 3,792,061; 3,799,877; 3,836,470; 3,836,471; 3,838,050; 3,838,052; 3,879,308; 3,912,764; 3,927,041; 4,062,786; 4,102,798; 4,110,349; 4,113,639; 4,116,875; 4,116,876; 4,123,373; 4,151,173; 4,176,063; 4,169,836; 4,263,153; 4,292,184; 4,379,914; 4,463,168; 4,486,326; 4,502,970; 4,517,104; 4,532,058; 4,536,547 and Reissue 26330.

SUMMARY OF THE INVENTION

Despite the efficacy of prior art dispersant and oleaginous compositions, there is a need for more efficient and less costly dispersants which can either perform better, or perform well at lower dispersant levels. Accordingly, it is a principal object of this invention to provide novel lactone adduct based dispersants which are effective, and readily prepared under typical dispersant manufacturing conditions.

Another object is to provide a novel class of poly (C₅ -C₉ lactone) adduct dispersants.

Another object is to provide a process for preparing efficient dispersants by reacting a hydrocarbyl substituted dicarboxylic acid, anhydride, etc. with a lactone adduct formed by reacting a C₅ -C₉ lactone with a polyamine, a polyol, an amino alcohol or a mixture thereof.

A further object is to provide lubricant compositions and concentrates containing the novel C₅ -C₉ lactone based dispersants of this invention.

Yet another object is to provide a novel class of oil soluble dispersants from polyalkylene substituted acylating agents which have at least one group in their structure which is reactive with an intermediate adduct formed by reacting a C₅ -C₉ lactone with a polyamine, a polyol, an amino alcohol, or a mixture thereof.

Still another object is to provide C₅ -C₉ lactone-polyol adducts which have been post-reacted with polyalkylene substituted succinic acylating agents, as well as lubricant compositions and concentrates containing the post-reacted adducts.

Another object is to provide C₅ -C₉ lactone-polyamine adducts which have been post-reacted with polyalkylene substituted succinic acylating agents, as well as lubricant compositions and concentrates containing the post-reacted adducts.

Still another object is to provide C₅ -C₉ lactone-amino alcohol adducts which have been post-reacted with polyalkylene substituted succinic acylating agents, as well as lubricant compositions and concentrates containing the post-reacted adducts.

Still another object is to provide metal complexes and post-treated derivatives, e.g., borated derivatives, of the C₅ -C₉ lactone derived dispersants of this invention, as well as lubricant compositions and concentrates containing such post-treated derivatives.

The manner in which these and other objects can be achieved will be apparent from the detailed description of the invention which appears hereinbelow.

In one aspect of this invention, one or more of the above objects can be achieved by reacting a C₅ -C₉ lactone with a polyamine to yield a hydroxyl terminated amide structure containing a sequence of methylene units between the hydroxyl and amide groups, and thereafter reacting the hydroxyl terminated amide structure with polyolefin substituted dicarboxylic acylating agent, wherein the polyolefin has a number average molecular weight of about 300 to about 10,000, and wherein the acylating agent contains from about 0.70 to about 2.0 dicarboxylic acid producing moieties, preferably acid anhydride moietiesd per equivalent weight of polyolefin.

In another aspect, one or more of the objects of this invention can be achieved by heating a C₅ -C₉ lactone such as E-caprolactone at a temperature of at least about 50° C., and preferably from about 75° C. to about 180° C. with a polyamine, and then heating the resulting adduct with a polyalkylene succinic acid or anhydride wherein the polyalkylene is characterized by a number average molecular weight of about 300-10000 and wherein the polyalkylene succinic acid or anhydride is characterized by the presence within its structure of from about 0.7 to about 2.0 succinic acid or succinic acid derivative moieties for each equivalent weight of polyalkylene; and, in a further aspect, one or more objects of this invention are achieved by providing acylated C₅ -C₉ lactone adducts produced by such a process.

One or more objects of this invention can be illustrated in connection with the reaction between a C₅ -C₉ lactone such as E-caprolactone and a polyamine such as tetraethylene pentamine (TEPA) to form a hydroxyl terminated amide structure containing a sequence of five methylene units between the hydroxyl unit and the amide, followed by the reaction between the hydroxyl terminated amide structure and a polyisobutenyl succinimide-amide dispersant. This process results in the formation of a mixture of reaction products which is believed to include lactone modified amide-imide- and ester-containing structures, and may be characterized by the following general equation: ##STR2## where PIB represents polyisobutylene having a number average molecular weight (M_(n)) of from about 300 to about 10,000.

Still other objects can be illustrated in connection with the reaction between E-caprolactone and a polyol such as pentaerythritol to form a polyol ester intermediate, which intermediate is then reacted with a PIBSA to form a PIBSA-polyolcaprolactone dispersant. This process results in the formation of a mixture of reaction products which is believed to include lactone modified ester containing structures, and may be characterized by the following general equations: ##STR3## where PIB represents polyisobutenyl having a number average molecular weight of from about 300 to about 10,000.

Still other objects can be illustrated in connection with the reaction between E-caprolactone and an amino alcohol such as 2-amino-2-(hydroxymethyl)-1,3-propanediol (THAM) to form a polyol amide which, upon heating, forms a hydroxyoxazoline intermediate. Either the polyol amide or the hydroxy-oxazoline intermediate can then be reacted with a PIBSA to form a PIBSA-bis-ester oxazoline dispersant. This process can be characterized by the following general equations: ##STR4##

The novel products of this invention are useful per se as an additive, e.g., a dispersant additive, for example, in the same manner as disclosed in U.S. Pat. No. 3,219,666 where prior art derivatives of polyalkenyl succinic acids and nitrogen compounds are used as dispersant/detergents in lubricants, especially lubricants intended for use in the crankcase of internal combustion engines, gears, and power transmitting units. Accordingly, one or more objects of this invention are achieved by providing lubricating oil compositions, e.g., automatic transmission fluids, heavy duty oils suitable for use in the crankcases of gasoline and diesel engines, etc. containing the novel C₅ -C₉ lactone based products of this invention. Such lubricating oil compositions may contain additional additives such as viscosity index improves, antioxidants, corrosion inhibitors, detergents, pour depressants, antiwear agents, etc.

Still further objects are achieved by providing concentrate compositions comprising from about 20 to about 80 weight % of a normally liquid, substantially inert, organic solvent/diluent, e.g., mineral lubricating oil, or other suitable solvent/diluent and from about 20 to about 80 weight % of a C₅ -C₉ lactone based dispersant, as mentioned above and described in more detail hereinafter.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The Lactone Material

Useful lactone compounds for forming the intermediates or lactone adducts by reaction with a polyamine, polyol, or amino alcohol include polymerizable lactones having at least five carbon atoms in the lactone ring, e.g., 5 to 9 carbon atoms. The lactone may be substituted or unsubstituted and the substituents, if any may comprise, for example, alkyl, aryl, aralkyl, cycloalkyl, alkoxy or other groups which would not interfere with the ring opening reaction and adduct formation. The preferred lactones have no more than two substituent groups, and the more preferred lactones are unsubstituted.

Non-limited examples of the useful lactones include delta-valerolactone, methyl-delta-valerolactone, E-caprolactone, methyl-E-caprolactone, dimethyl-E-caprolactone, methoxy-E-caprolactone, cyclohexyl-E-caprolactone, methylbenzyl-E-caprolactone, caprylolactone, methyl-caprylolactone, and the like, with E-caprolactone being particularly preferred.

Reaction of the Lactone with a Polyamine

The above lactones such as E-caprolactone are cyclic esters which can be reacted with a polyamine to yield hydroxyl terminated amide adduct structure containing a sequence of methylene units between the hydroxy and the amide. In the case of E-caprolactone, which is a preferred lactone for use in this invention, the adduct contains a sequence of five methylene units between the hydroxyl and the amide groups. The stoichiometry of the lactone and polyamine determines the length of the polyester sequence in the resulting adducts as can be appreciated from Equation 3 above. Once these lactone-polyamine adducts are formed, reaction with an acylating agent such as a PIBSA can be effected through the hydroxyl groups thereby forming an ester link with the acylating agent. The resulting materials, which are illustrated generally in Equation 4, display excellent bench test and engine test results.

The chemistry of the lactone-polyamine reaction is such that primary amino functionality is more reactive than the secondary amino functionality in the polyamine structure and therefore the amide structure illustrated in Equation 3 will be the favored product. It is also possible, however, that the secondary amino functionality or the hydroxyl functionality of the resulting adducts can react with further molecules of the lactone to form a diversity of structures.

In the reactions discussed above, the degree of polymerization (DP) of the lactone monomer i.e., the sequence of lactone units in a row in the lactone adduct, may vary depending upon the intended application. At DP's of much greater than about 10 the dispersants formed from the lactone adducts can exhibit crystallinity; a characteristic which is undesirable in an oil soluble dispersant due to the consequent high viscosity, or even solid oil products which can be obtained. However, at lower DP's oil soluble adducts posessing low viscosity and desirable sludge and varnish inhibition characteristics are obtained. Accordingly, regardless of the identity of the lactone adduct, the average degree of polymerization (DP) should be between about 0.2 and about 100, more preferably between about 0.2 and about 50, and most preferably between 0.5 and about 20. For optimal dispersant performance sequences of from about 1 to about 5 lactone units in a row are preferred. The degree of polymerization can be controlled by controlling the reaction conditions, including the mole ratio of lactone to amine compound, amount of catalyst employed, and the like.

Useful amine compounds for reaction with the lactone material include polyamines of about 2 to 60, e.g. 3 to 20, most preferably 3 to 10, total carbon atoms in the molecule. These amines may be hydrocarbyl amines or may be hydrocarbyl amines including other noninterfering groups, e.g., alkoxy groups, amide groups, nitrile groups, imidazoline groups, and the like. Preferred amines are aliphatic saturated amines, including those of the general formula: ##STR5## wherein R and R' are independently selected from the group consisting of hydrogen, C₁ to C₂₅ straight or branched chain alkyl radicals, C₁ to C₁₂ alkoxy C₂ to C₆ alkylene radicals: and C₁ to C₁₂ alkylamino C₂ to C₆ alkylene radicals. Each s is the same or a different number of from 2 to 6, preferably 2 to 4; and t is a number of from 0 to 10, preferable 2 to 7. If t=0, then at least one of R or R¹ must be H such that there are at least two of either primary or secondary amino groups.

Non-limiting examples of suitable amine compounds include: 1,2-diaminoethane, 1,3-diaminopropane, 1,4-diaminobutane, 1,6-diaminohexane, polyethylene amines such as diethylene triamine, triethylene tetramine, tetraethylene pentamine, polypropylene amines such as 1,2-propylene diamine, di-(1,2-propylene)triamine, di-(1,3-propylene)triamine, N,N-dimethyl-1-1,3-diaminopropane, N,N-di-(2-aminoethyl)ethylene diamine; N-dodecyl-1-1,3-propane diamine, di-, and tri-tallow amines, amino morpholines such as N-(3-aminopropyl morpholine, etc.

Other useful amine compounds include: alicyclic diamines such as 1,4-di(aminomethyl)cyclohexane, and heterocyclic compounds such as morpholines, imidazolines, and N-aminolakyl piperazines of the general formula: ##STR6## wherein G is independently selected from the group consisting hydrogen and omega-(nontertiary)aminoalkylene radicals of from 1 to 3 carbon atoms, and p is a number of from 1 to 4. Nonlimiting examples of such amines include 2-pentadecyl imidazoline, N-(2-aminoethyl)piperazine, etc.

Commercial mixtures of amine compounds advantageously may be used. For example, one process for preparing alkylene amines involves the reaction of an alkylene dihalide (such as ethylene dichloride or propylene dichloride) with ammonia, which results in a complex mixture of alkylene amines wherein pairs of nitrogens are joined by alkylene groups, forming such compounds as diethylene triamine, triethylenetetramine, tetraethylene pentamine and isomeric piperazines. A low cost mixture of poly(ethyleneamine) compounds averaging about 5 to 7 nitrogen atoms per molecule are available commercially under trade names as "Polyamine H", "Polyamine 400", "Dow Polyamine E-100", etc.

Useful amines also include polyoxalkylene polyamines such as those of the formulas: ##STR7## where m has a value of about 3 to 70 and preferably 10 to 35: and ##STR8## where n has a value of about 1 to 40 with the provision that the sum of all the n's is from about 3 to about 70 and preferably from about 6 to about 35, R is a substituted saturated hydrocarbon radical of up to 10 carbon atoms, wherein the number of substituents on the R group is represented by the value of "a", which is a number from 3 to 6. The alkylene gorups in either formula III or IV may be straight or branched chain containing about 2 to 7, and preferably about 2 to 4 carbon atoms.

The above polyoxyalkylene polyamines, preferably polyoxyalkylene diamines and polyoxyalkylene triamines, may have average molecular weights ranging from about 200 to about 4,000 and preferably from about 400 to about 2,000. The preferred polyoxyalkylene polyamines include the polyoxyethylene and polyoxypropylene diamines and the polyoxypropylene triamines having average molecular weight ranging from about 200 to 2,000. The polyoxyalkylene polyamines are commercially available and may be obtained, for example, from the Jefferson Chemical Company, Inc. under the trace name "Jeffamines D-230, D-400, D-1000, D-2000, T-403", etc.

The polyamine is readily reacted with the lactone, with or without a catalyst, simply by heating a mixture of the lactone and polyamine in a reaction vessel in the absence of a solvent at a temperature of about 30° C. to about 200° C., more preferably to a temperature of about 75° C. to about 180° C., and most preferably at about 90° C. to about 160° C., for a sufficient period of time to effect reaction. Optionally, a solvent for the lactone, polyamine and/or adduct can be employed to control viscosity and or reaction rates.

In one preferred embodiment of the invention, the C₅ -C₉ lactone such as E-caprolactone is reacted with a polyamine such as tetraethylene pentamine in a 2:1 molar ratio in accordance with the Equation above. However, in accordance with the reaction scheme illustrated in equation 3 above, it will be appreciated that the mole ratio of lactone to polyamine can be varied widely as a means for controlling the length of the sequence of lactone units in the adduct. In this latter regard, the mole ratio of lactone to polyamine may vary from about 10:1 to about 0.1:1, more preferably from about 4:1 to about 0.2:1, and most preferably from about 2:1 to about 0.4:1.

Catalysts useful in the promotion of the above-identified lactone-polyamine reactions are selected from the group consisting of stannous octanoate, stannous hexanoate, stannous oxalate, tetrabutyl titanate, a variety of metal organic based catalyst acid catalysts and amine catalysts, as described on page 266, and forward in a book chapter authorized by R. D. Lundberg and E. F. Cox entitled, "Kinetics and Mechanisms of Polymerization: Ring Opening Polymerization", edited by Frisch and Reegen, published by Marcel Dekker in 1969, wherein stannous octanoate is an especially preferred catalyst. The catalyst is added to the reaction mixture at a concentration level of about 50 to about 10,000 parts of catalyst per one million parts by weight of the total reaction mixture.

REACTION OF THE LACTONE WITH A POLYOL

In another aspect of the invention, the lactone adduct dispersant precursors are prepared by reacting the above discussed C₅ -C₉ lactones with a polyol instead of with a polyamine.

Suitable polyol compounds which can be used in this esterification reaction include aliphatic polyhydric alcohols containing up to about 100 carbon atoms and about 2 to about 10 hydroxyl groups. These alcohols can be quite diverse in structure and chemical composition, for example, they can be substituted or unsubstituted, hindered or unhindered, branched chain or straight chain, etc. as desired. Typical alcohols are alkylene glycols such as ethylene glycol, propylene glycol, trimethylene glycol, butyl glycol, and polyglycol such as diethylene glycol, triethylene glycol, tetraethylene glycol, dipropylene glycol, tripropylene glycol, dibutylene glycol, tributylene glycol, and other alkylene glycols and polyalkylene glycols in which the alkylene radical contains from two to about eight carbon atoms. Other useful polyhydric alcohols include glycerol, monomethyl ether of glycerol, penthaerythritol, dipentaerythritol, tripentaerythritol, 9,10-dihydroxystearic acid, the ethyl ester of 9,10-dihydroxystearic acid, 3-chloro-1,2-propanediol, 1,2-butanediol, 1,4-butanediol, 2,3-hexanediol, 2,3-hexanediol, pinacol, tetrahydroxy pentane, erythritol, arabitol, sorbitol, mannitol, 1,2-cyclohexanediol, 1,4-cyclohexanediol, 1,4-(2-hydroxyethyl)-cyclohexane, 1,4-dihydroxy-2-nitrobutane, 1,4-di-(2-hydroxyethyl)-benzene, the carbohydrates such as glucose, rhamnose, mannose, glyceraldehyde, and galactose, and the like, amino alcohols such as di-(2-hydroxyethyl)amine, tri-(3-hydroxypropyl)amine, N,N'-di-(hydroxyethyl)-ethylenediamine, copolymer of allyl alcohol and styrene, N,N-di-(2-hydroxylethyl)glycine and esters thereof with lower mono- and polyhydric aliphatic alcohols etc.

Included within the group of aliphatic alcohols are those alkane polyols which contain ether groups such as polyethylene oxide repeating units, as well as those polyhydric alcohols containing at least three hydroxyl groups, at least one of which has been esterified with a mono-carboxylic acid having from eight to about 30 carbon atoms such as octanoic acid, oleic acid, stearic acid, linoleic acid, dodecanoic acid, or tall oil acid. Examples of such partially esterified polyhydric alcohols are the mono-oleate of sorbitol, the mono-oleate of glycerol, the mono-stearate of glycerol, the di-stearate of sorbitol, and the di-dodecanoate of erythritol.

A preferred class of ester intermediates are those prepared from aliphatic alcohols containing up to 20 carbon atoms, and especially those containing three to 15 carbon atoms. This class of alcohols includes glycerol, erythritol, pentaerythritol, dipentaerythritol, tripentaerythritol, gluconic acid, glyceraldehyde, glucose, arabinose, 1,7-heptanediol, 2,4-heptanediol, 1,2,3-hexanetriol, 1,2,4-hexanetriol, 1,2,5-hexanetriol, 2,3,4-hexanetriol, 1,2,3-butanetriol, 1,2,4-butanetriol, quinic acid, 2,2,6,6-tetrakis(hydroxymethyl)-cyclohexanol, 1,10-decanediol, digitalose, and the like. The esters prepared from aliphatic alcohols containing at least three hydroxyl groups and up to fifteen carbon atoms are particularly preferred.

An especially preferred class of polyhydric alcohols for preparing the lactone adducts used as starting materials in the present invention are the polyhydric alkanols containing three to 15, especially three to six carbon atoms and having at least three hydroxyl groups. Such alcohols are exemplified in the above specifically identified alcohols and are represented by glycerol, erythritol, pentaerythritol, mannitol, sorbitol, 1,2,4-hexanetriol, and tetrahydroxy pentane and the like.

The polyol is readily reacted with C₅ -C₉ lactone e.g., E-caprolactone, by heating a mixture of the polyol and lactone in a reaction vessel in the absence of a solvent at a temperature of about 50° C. to about 200° C., more preferably to a temperature of about 75° C. to about 180° C., and most preferable at about 90° C. to about 160° C., for a sufficient period of time to effect reaction. Optionally, a solvent for the lactone, polyol and/or the resulting adduct may be employed to control viscosity and/or the reaction rates.

In one preferred embodiment of the invention, the C₅ -C₉ lactone, e.g., E-caprolactone is reacted with a polyol, e.g., pentaerythritol in accordance with the reaction scheme illustrated in Equation 5 wherein a 1:1 mole ratio of caprolactone to pentaerythritol is shown. In practice, the ratio of lactose to polyol may vary considerably as a means of controlling the length of the sequence of the lactone units in the adduct. For example, the mole ratio of lactone to polyol may vary from about 10:1 to about 0.1:1, more preferable from about 5:1 to about 0.2:1, and most preferably from about 2:1, to about 0.4:1. As is the case with the lactone/polyamine adducts, it is preferable to maintain the average degree of polymerization of the lactone monomer below about 100, with a degree of polymerization on the order of from about 0.2 to about 50 being preferred, and from about 0.2 to about 20 being more preferred. For optimum dispersant performance, sequences of from about 1 to about 5 lactone units in a row are preferred.

Catalysts useful in the promotion of the lactone-polyol reactions are the same as those which are useful in connection with the lactone-polyamine reactions discussed above. The catalyst may be added to the reaction mixture at a concentration level of from about 50 to about 10,000 parts of catalyst per one million parts by weight of total reaction mixture.

REACTION OF THE LACTONE WITH AN AMINO ALCOHOL

In a manner analogous to that described for the lactone-polyamine reaction and for the lactone-polyol reaction, the C₅ -C₉ lactone can be reacted with an amino alcohol to form an adduct or intermediate which can be further reacted with an acylating agent to form the dispersants of this invention.

Suitable amino alcohol compounds which can be reacted with the lactone include those containing up to about 50 total carbon atoms and preferably up to about 10 total carbon atoms, from 1 to about 5 nitrogen atoms, preferably from 1 to 3 nitrogen atoms, and from 1 to about 15 hydroxyl groups, preferably from about 1 to 5 hydroxyl groups. Preferred amino alcohols include the 2,2-disubstituted-2-amino-1-alkanols having from two to three hydroxy groups and containing a total of 4 to 8 carbon atoms. These amino alcohols can be represented by the formula: ##STR9## wherein X is an alkyl or hydroxyalkyl group with the alkyl groups having from 1 to 3 carbon atoms wherein at least one, and preferably both, of the X substituents is a hydroxyalkyl group of the structure --(CH₂)_(n) OH, n being 1 to 3. Examples of such amino alcohols include: 2-amino-2-methyl-1,3 propanediol; 2-amino-2-ethyl-1,3-propanediol; and 2-amino-2-(hydroxymethyl)1,3-propanediol; the latter also being known as THAM or tris(hydroxymethyl)amino methane. THAM is particularly preferred because of its effectiveness, availability and low cost.

The amino alcohol is readily reacted with the C₅ -C₉ lactone by heating a mixture of the lactone and amino alcohol in a reaction vessel in the absence of a solvent at a temperature of about 50° C. to about 200° C., more prferably at temperature of about 75° C. to about 180° C., and most preferably at about 90° C. to about 160° C., for a sufficient period of time to effect reaction. Optionally, a solvent for the lactone, amino alcohol and/or the reaction product may be used to control viscosity and/or the reaction rates.

In one preferred embodiment of the invention, the C₅ -C₉ lactone, e.g., E-caprolactone is reacted with an amino alcohol, e.g., THAM in accordance with the reaction scheme illustrated in Equation 7. As shown in Equation 7, one mole of E-caprolactone is reacted with one mole of THAM to form a polyhydroxy terminated amide which, upon further heating, rearranges to form a hydroxyoxazoline.

It will be appreciated that the mole ratio of lactone to amino alcohol may be varied considerably and that the reaction product, in most cases, will comprise a mixture of adducts. In this latter regard, it is contemplated that the mole ratio of lactone to amino alcohol may vary from about 10:1 to about 0.1:1, more preferably from about 5:1 to about 0.5:1, and most preferably from about 2:1 to about 0.6:1. It also contemplated that the average degree of polymerization of the lactone in the lactone/amino alcohol adduct preferably will be less than about 100. Preferably, the average degree of polymerization is from about 0.2 to about 50, and more preferably from about 0.2 to about 20. For optimum dispersant performance, sequences of from about 1 to about 5 lactone units in a row are preferred.

Catalysts useful in the promotion of the lactone-amino alcohol reactions are the same as those which are useful in connection with the lactone-polyamine and lactone-polyol reactions, and corresponding amounts of catalyst may be employed.

THE ACYLATING AGENTS

The acylating agents which may be reacted with the lactone-polyamine, lactone-polyol and/or lactone-amino alcohol adducts to form the dispersant additives of the invention are dicarboxylic acid materials, e.g., acid, anhydride or ester material, which are substituted with a long chain hydrocarbyl group, generally a polyolefin, and which contain 0.7 to 2.0, preferably 1.00 to 1.5, e.g, 1.05 to 1.3 moles, per mole of polyolefin of an alpha or beta unsaturated C₄ to C₁₀ dicarboxylic acid or anhydride or ester thereof, such as fumaric acid, itaconic acid, maleic acid, maleic anhydride, chloromaleic acid, dimethyl fumarate, chloromaleic anhydride, etc.

Preferred olefin polymer substituents are polymers comprising a major molar amount of C₂ to C₁₀, e.g., C₂ to C₅ mono-olefin. Such olefins include ethylene, propylene, butylene, isobutylene, pentene, octene-1, styrene, etc. The polymers can be homopolymers such as polyisobutylene, as well as copolymers of two or more of such olefins such as copolymers of: ethylene and propylene; butylene and isobutylene; propylene and isobutylene; etc. Other copolymers include those in which a minor molar amount of the copolymer monomers, e.g., 1 to 10 mole %, is a C₄ to C₁₈ diolefin, e.g., a copolymer of isobutylene and butadiene; or a copolymer of ethylene, propylene and 1,4-hexadiene, etc.

In some cases, the olefin polymer may be completely saturated, for example an ethylenepropylene copolymer made by a Ziegler-Natta synthesis using hydrogen as a moderator to control molecular weight.

The olefin polymers will usually have number average molecular weights within the range of about 300 and about 10,000, more usually between 500 and about 7,000. Particularly useful olefin polymers have number average molecular weights within the range of about 500 and 3000, and more preferable between about 900 and about 2500, with approximately one terminal double per polymer chain. An especially useful olefin polymer for a highly potent dispersant additive made in accordance with this invention is polyisobutylene. The number average molecular weight for such polymers can be determined by several known techniques. A convenient method for such determination is by gel permeation chromatography (GPC) which additionally provides molecular weight distribution information, see W. W. Yau, J. J. Kirkland and D. D. Bly, "Modern Size Exclusion Liquid Chromatography", John Wiley and Sons, New York, 1979.

Processes for reacting the olefin polymer with the C₄ -C₁₀ unsaturated dicarboxylic acid, anhydride or ester to form the acylating agents to be used in this invention are known in the art. For example, the olefin polymer and the dicarboxylic acid material may be simply heated together as disclosed in U.S. Pat. Nos. 3,361,673 and 3,401,118 to cause a thermal "ene" reaction to take place. Or, the olefin polymer can be first halogenated, for example, chlorinated or brominated to about 1 to 8, preferably 3 to 7 wt. % chlorine, or bromine, based on the weight of polymer, by passing the chlorine or bromine through the polyolefin at a temperature of 100 to 250, e.g., 140° to 225° C. for about 0.5 to 10, preferably 1 to 7 hours. The halogenated polymer may then be reacted with sufficient unsaturated acid or anhydride at 100° to 250° C., usually about 140° to 180° C. for about 0.5 to 10, e.g., 3 to 8 hours, so the product obtained will contain about 1.0 to 1.5, preferably 1.06 to 1.20, eg., 1.10 moles of the unsaturated acid per mole of the halogenated polymer. Processes of this general type are taught in U.S. Pat. Nos. 3,087,436; 3,172,892, 3,272,746 and others.

Alternatively, the olefin polymer, and the unsaturated acid material are mixed and heated while adding chlorine to the hot material. Processes of this type are disclosed in U.S. Pat. Nos. 3,215,707; 3,231,587; 3,912,764; 4,110,349; 4,234,435; and in U.K. Pat. No. 1,440,219.

By the use of halogen, about 65 to 95 wt. % of the polyolefin, e.g., polyisobutylene will normally reacted with the dicarboxylic acid material. Upon carrying out a thermal reaction usually only about 50 to 75 wt. % of the polyisobutylene will react. Chlorination helps increase the reactivity. For convenience, the aforesaid functionality ratios of dicarboxylic acid producing units to polyolefin of 0.7 to 2.0 are based upon the total amount of polyolefin, that is, the total of both the reacted and unreacted polyolefin, used to make the product.

REACTION OF THE ACYLATING AGENT WITH THE LACTONE ADDUCT

In order to form the lactone based dispersants of the present invention, the long chain hydrocarbyl substituted dicarboxylic acid material, must be reacted with a lactone-polyamine adduct, a lactone-polyol adduct, a lactone-amino alcohol adduct or a mixture thereof.

All of the above lactone adducts are readily reacted with the hydrocarbyl substituted dicarboxylic acid material, e.g., alkenyl succinic anhydride, by heating an oil solution containing 5 to 95 wt.% of dicarboxylic acid material to about 100° to 250° C., preferably 160° to 210° C., generally for 1 to 10, e.g., 2 to 6 hours until the desired amount of water is removed. Reaction ratios can vary considerably, depending upon the reactants, the amount of excess lactone adduct, the type of bonds formed, etc. Generally from 0.2 to 2, preferably 0.4 to 1.5 e.g. about 1 mole of lactone adduct, .g., E-caprolactone/pentaerylthritol is used per mole of the dicarboxylic acid moiety content, e.g., grafted maleic anhydride content. For example, if one mole of olefin were reacted with sufficient maleic anhydride to add 1 mole of maleic anhydride groups per mole of olefin, then about 1 mole of lactone adduct preferably would be used to react with the olefin succinic anhydride; i.e., about 1 mole of polyol per mole of dicarboxylic acid moiety would be used. Variations beyond these ratios can be practiced, but normally such variations would not be desirable.

The reaction between the lactone-polyamine adduct and the hydrocarbyl substituted dicarboxylic acid material may be exemplified by the following reaction scheme which represents the esterification of polyisobutenyl succinic anhydride with an E-caprolactone/tetraethylene pentamine adduct: ##STR10## where PIB is polyisobutylene.

In an alternative embodiment, the reaction between the lactone-polyol adduct and the hydrocarbyl substituted dicarboxylic acid material may be exemplified by the following reaction scheme which represents the esterification of polyisobutenyl succinic anhydride with an E-caprolactone/pentaerythritol adduct: ##STR11## where PIB represents polyisobutylene.

Dispersants of the type shown in Equation 6 can be prepared at lower reaction temperatures than conventional polisobutylene succinic anhydride/pentaerythritol dispersants because the E-caprolactone/pentaerythritol adduct is much more soluble in the diluents that are employed in the reaction.

In still another alternative, a lactone/amino alcohol adduct is reacted with the hydrocarbyl substituted dicarboxylic acid material to from a bis-oxazoline type dispersant which is more stable on long term storage at elevated temperatures than conventional hydrocarbyl substituted dicarboxylic acid material/bis-oxazoline dispersants.

The preparation of the bis-oxazoline type dispersants of this invention can be illustrated by the reactions between polyisobutylene succinic anhydride and E-caprolactone/THAM adducts as follows: ##STR12##

Further aspects of the present invention reside in the formation of metal complexes and other post-treatment derivatives, e.g., borated derivatives, of the novel additives prepared in accordance with this invention. Suitable metal complexes may be formed in accordance with known techniques of employing a reactive metal ion species during or after the formation of the present C₅ -C₉ lactone derived dispersant materials. Complex-forming metal reactants include the nitrates, thiocyanates, halides, carboxylates, phosphates, thio-phosphates, sulfates, and borates of transition metals such as iron, cobalt, nickel, copper, chromium, manganese, molybdenum, tungsten, ruthenium, palladium, platinum, cadmium, lead, silver, mercury, antimony and the like. Prior art disclosures of these complexing reactions may be found in U.S. Pat. No. 3,306,908 and Re. No. 26,433.

Post-treatment compositions include those formed by reacting the novel additives of the present invention with one or more post-treating reagents, usually selected from the group consisting of boron oxide, boron oxide hydrate, boron halides, boron acids, sulfur, sulfur chlorides, phosphorous sulfides and oxides, carboxylic acid or anhydride acylating agents, epoxides and episulfides and acrylonitriles. The reaction of such post-treating agents with the novel additives of this invention is carried out using procedures known in the art. For example, boration may be accomplished in accordance with the teachings of U.S. Pat. No. 3,254,025 by treating the C₅ -C₉ lactone derived additive compound with a boron oxide, halide, ester or acid. Treatment may be carried out by adding about 1-3 wt.% of the boron compound, preferably boric acid, and heating and stirring the reaction mixture at about 135° C. to 165° C. for 1 to 5 hours followed by nitrogen stripping and filtration, if desired. Mineral oil or inert organic solvents facilitate the process.

THE COMPOSITIONS

The lactone derived additives of the present invention have been found to possess very good dispersant properties as measured herein in a wide variety of environments.

Accordingly, the lactone derived adducts are used by incorporation and dissolution into an oleaginous material such as fuels and lubricating oils.

When the dispersants of this invention are used in normally liquid petroleum fuels such as middle distillates boiling from about 150° to 800° F., including kerosene, diesel fuels, home heating fuel oil, jet fuels, etc., a concentration of the additive in the fuel in the range of typically from about 0.001 to about 0.5, and preferably 0.001 to about 0.1 weight percent, based on the total weight of the composition, will usually be employed.

The lactone derived dispersants find their primary utility in lubricating oil compositions which employ a base oil in which the additives are dissolved or dispersed.

Such base oils may be natural or synthetic although the natural base oils will derive a greater benefit.

Thus, base oils suitable for use in preparing lubricating compositions of the present invention include those conventionally employed as crankcase lubricating oils for spark-ignited and compression-ignited internal combustion engines, such as automobile and truck engines, marine and railroad diesel engines, and the like. Advantageous results are also achieved by employing the dispersant additives of the present invention in base oils conventionally employed in and/or adapted for use as power transmitting fluids such as automatic transmission fluids, tractor fluids, universal tractor fluids and hydraulic fluids, heavy duty hydraulic fluids, power steering fluids and the like. Gear lubricants, industrial oils, pump oils and other lubricating oil compositions can also benefit from the incorporation therein of the additives of the present invention.

Thus, the additives of the present invention may be suitably incorporated into synthetic base oils such as alkyl esters of dicarboxylic acids, polyglycols and alcohols, polyalphaolefins, alkyl benzenes, organic esters of phosphoric acids, polysilicone oils, etc.

Natural base oils include mineral lubricating oils which may vary widely as to their crude source, e.g., whether paraffinic, naphthenic, mixed, paraffinic-naphthenic, and the like; as well as to their formation, e.g., distillation range, straight run or cracked, hydrofined, solvent extracted and the like.

More specifically, the natural lubricating oil base stocks which can be used in the compositions of this invention may be straight mineral lubricating oil or distillates derived from paraffinic, naphthenic, asphaltic, or mixed base crudes, or, if desired, various blends oils may be employed as well as residuals, particularly those from which asphaltic constituents have been removed. The oils may be refined by conventional methods using acid, alkali, and/or clay or other agents such as aluminum chloride, or they may be extracted oils produced, for example, by solvent extraction with solvents of the type of phenol, sulfur dioxide, furfural, dichlorodiethyl ether, nitrobenzene, crotonaldehyde, etc.

The lubricating oil base stock conveniently has a viscosity of typically about 2.5 to about 12, and preferably about 2.5 to about 9 cs. at 100° C.

Thus, the lactone derived additives of the present invention can be employed in a lubricating oil composition which comprises lubricating oil, typically in a major amount, and the dispersant additive, typically in a minor amount, which is effective to impart enhanced dispersancy, relative to the absence of the additive. Additional conventional additives selected to meet the particular requirements of a selected type of lubricating oil composition can be included as desired.

The dispersants of this invention are oil-soluble, dissolvable in oil with the aid of a suitable solvent, or are stably dispersible materials. Oil-soluble, dissolvable, or stably dispersible as that terminology is used herein does not necessarily indicate that the materials are soluble, dissolvable, miscible, or capable of being suspended in oil in all proportions. It does mean, however, that the dispersant additives, for instance, are soluble or stably dispersible in oil to an extent sufficient to exert their intended effect in the environment in which the oil is employed. Moreover, the additional incorporation of other additives may also permit incorporation of higher levels of a particular dispersant, if desired.

Accordingly, while any effective amount of the dispersant additives can be incorporated into the lubricating oil composition, it is contemplated that such effective amount be sufficient to provide said lube oil composition with an amount of the additive of typically from about 0.10 to about 15 e.g., 0.1 to 10, and preferably from about 0.1 to about 7 wt.%, based on the weight of said composition.

The dispersant additives of the present invention can be incorporated into the lubricating oil in any convenient way. Thus, they can be added directly to the oil by dispersing, or dissolving the same in the oil at the desired level of concentration typically with the aid of a suitable solvent such as toluene, or tetrahydrofuran. Such blending can occur at room temperature or elevated temperatures. Alternatively, the dispersant additives may be blended with a suitable oil-soluble solvent and base oil to form a concentrate, and then blending the concentrate with lubricating oil base stock to obtain the final formulation. Concentrates will typically contain from about 20 to about 60 wt.%, by weight dispersant additive, and typically from about 80 to about 20%, preferably from about 60 to about 20% by weight base oil, based on the concentrate weight.

The lubricating oil base stock for the dispersant additives of the present invention typically is adapted to perform a selected function by the incorporation of additives therein to form lubricating oil compositions (i.e., formulations).

Representative additives typically present in such formulations include viscosity modifiers, corrosion inhibitors, oxidations, inhibitors, friction modifiers, other dispersants, anti-foaming agents, anti-wear agents, pour point depressants, detergents, rust inhibitors and the like.

Viscosity modifiers impart high and low temperature operability to the lubricating oil and permit it to remain shear stable at elevated temperatures and also exhibit acceptable viscosity or fluidity at low temperatures.

Viscosity modifiers are generally high molecular weight hydrocarbon polymers including polyesters. The viscosity modifiers may also be derivatized to include other properties or functions, such as the addition of dispersancy properties.

These oil soluble viscosity modifying polymers will generally have number average molecular weights of from 10³ to 10⁶, preferably 10⁴ to 10⁶, e.g., 20,000 to 250,000, as determined by gel permeation chromatography or membrane osmometry.

Representative examples of suitable viscosity modifiers are any of the types known to the art including polyisobutylene, copolymers of ethylene and propylene, polymethacrylates, methacrylate copolymers, copolymers of an unsaturated dicarboxylic acid and vinyl compound, interpolymers of styrene and acrylic esters, and styrene/isoprene copolymers.

Corrosion inhibitors, also known as anti-corrosive agents, reduce the degradation of the metallic parts contacted by the lubricating oil composition. Illustrative of corrosion inhibitors are phosphosulfurized hydrocarbons and the products obtained by reaction of a phosphosulfurized hydrocarbon with an alkaline earth metal oxide or hydroxide, preferably in the presence of an alkylated phenol or of an alkylphenol thioester, and also preferably in the presence of carbon dioxide. Phosphosulfurized hydrocarbons are prepared by reacting a suitable hydrocarbon such as a terpene, a heavy petroleum fraction of a C₂ to C₆ olefin polymer such as polyisobutylene, with from 5 to 30 wt.% of a sulfide of phosphorus for 1/2 to 15 hours, at a temperature in the range of 150° to 600° F. Neutralization of the phosphosulfurized hydrocarbon may be effected in the manner taught in U.S. Pat. No. 1,969,324.

Oxidation inhibitors reduce the tendency of mineral oils to deteriorate in service which deterioration can be evidenced by the products of oxidation such as sludge and varnish-like deposits on the metal surfaces and by viscosity growth. Such oxidation inhibitors include alkaline earth metal salts of alkylphenolthioesters having preferably C₅ to C₁₂ alkyl side chains, e.g., calcium nonylphenol sulfide, barium t-octylphenyl sulfide, dioctylphenylamine, phenylalphanaphthylamine, phosphosulfurized or sulfurized hydrocarbons, etc.

Friction modifiers serve to impart the proper friction characteristics to lubricating oil compositions such as automatic transmission fluids.

Representative examples of suitable friction modifiers are found in U.S. Pat. No. 3,933,659 which discloses fatty acid esters and amides; U.S. Pat. No. 4,176,074 which describes molybdenum complexes of polyisobutyenyl succinic anhydride-amino alkanols; U.S. Pat. No. 4,105,571 which discloses glycerol esters of dimerized fatty acids; U.S. Pat. No. 3,779,928 which discloses alkane phosphonic acid salts; U.S. Pat. No. 3,778,375 which discloses reaction products of a phosphonate with an oleamide; U.S. Pat. No. 3,852,205 which discloses S-carboxyalkylene hydrocarbyl succinimide, S-carboxyalkylene hydrocarbyl succinamic acid and mixtures thereof; U.S. Pat. No. 3,879,306 which discloses N-hydroxyalkyl)alkenyl succinamic acids or succinimides; U.S. Pat. No. 3,932,290 which discloses reaction products of di-(lower alkyl) phosphites and epoxides; and U.S. Pat. No. 4,028,258 which discloses the alkylene oxide adduct of phosphosulfurized N-(hydroxyalkyl)alkenyl succinimides. The disclosures of the above references are herein incorporated by reference. The most preferred friction modifiers are succinate esters, or metal salts thereof, of hydrocarbyl substituted succinic acids or anhydrides and thiobis alkanols such as described in U.S. Pat. No. 4,344,853.

Dispersants maintain oil insolubles, resulting from oxidation during use, in suspension in the fluid thus preventing sludge flocculation and precipitationor deposition on metal parts. Suitable dispersants include high molecular weight alkyl succinates, the reaction product of oil-soluble polyisobutylene succinic anhydride with ethylene amines such as tetraethylene pentamine and borated salts thereof.

Pour point depressants lower the temperature at which the fluid will flow or can be poured. Such depressants are well known. Typically of those additives which usefully optimize the low temperature fluidity of the fluid are C₈ -C₁₈ dialkylfumarate vinyl acetate copolymers, polymethacrylates, and wax naphthalene. Foam control can be provided by an antifoamant of the polysiloxane type, e.g., silicone oil and polydimethyl siloxane.

Anti-wear agents, as their name implies, reduce wear of metal parts. Representatives of conventional anti-wear agents are zinc dialkyldithiophosphate, and zinc diaryldithiosphate.

Detergents and metal rust inhibitors include the metal salts of sulphonic acids, alkyl phenols, sulfurized alkyl phenols, alkyl salicylates, naphthenates and other oil soluble mon- and di-carboxylic acids. Highly basic (viz, overbased) metal salts, such as highly basic alkaline earth metal sulfonates (especially Ca and Mg salts) are frequently used as detergents. Representative examples of such materials, and their methods of preparation, are found in co-pending Ser. No. 235,920, filed Aug. 23, 1988, which is a continuation of Ser. No. 32,066, filed Mar. 27, 1987 (now abandoned), which, in turn, is a continuation of Ser. No. 754,001, filed July 11, 1985, (now abandoned) the disclosure of which is hereby incorporated by reference.

Some of these numerous additives can provide a multiplicity of effects, e.g., a dispersant-oxidantion inhibitor. This approach is well known and need not be further elaborated herein.

Compositions when containing these conventional additives are typically blended into the base oil in amounts which are effective to provide their normal attendant function. Representative effective amounts of such additives are illustrated as follows:

    ______________________________________                                         Additive           Vol %      Wt % AI                                          ______________________________________                                         Viscosity Modifier .01-4      .01-4                                            Corrosion Inhibitor                                                                               0.01-1     .01-1.5                                          Oxidation inhibitor                                                                               0.01-1     .01-1.5                                          Dispersant         0.1-7      0.1-8                                            Pour Point Depressant                                                                             0.01-1     .01-1.5                                          Anti-Foaming Agents                                                                               0.001-0.1  .001-0.15                                        Anti-Wear Agents   0.001-1    .001-1.5                                         Friction Modifiers 0.01-1     .01-1.5                                          Detergents/Rust Inhibitors                                                                        .01-2.5    .01-3                                            Mineral Oil Base   Balance    Balance                                          ______________________________________                                    

When other additives are employed, it may be desirable, although not necessary, to prepare additive concentrates comprising concentrated solutions or dispersions of the dispersant (in concentrate amounts hereinabove described), together with one or more of said other additives (said concentrate when constituting an additive mixture being referred to herein as an additive-package) whereby several additives can be added simultaneously to the base oil to form the lubricating oil composition. Dissolution of the additive concentrate into the lubricating oil may be facilitated by solvents and by mixing accompanied with mild heating, but this is not essential. The concentrate or additive-package will typically be formulated to contain the dispersant additive and optional additional additives in proper amounts to provide the desired concentration in the final formulation when the additive-package is combined with a predetermined amount of base lubricant. Thus, the dispersant of the present invention can be added to small amounts of base oil or other compatible solvents along with other desirable additives to form additive-packages containing active ingredients in collective amounts of typically from about 2.5 to about 90%, and preferably from about 5 to about 75%, and most preferably from about 8 to about 50% by weight additives in the appropriate proportions with the remainder being base oil.

The final formulations may employ typically about 10 wt.% of the additive-package with the remainder being base oil.

All of said weight percents expressed herein are based on active ingredient (A.I.) content of the additive, and/or upon the total weight of any additive-package, or formulation which will be the sum of the A.I. weight of each additive plus the weight of total oil or diluent.

This invention will be further understood by reference to the following examples, wherein all parts are parts by weight and all molecular weights and number average moleculare weights unless otherwise noted, and which include preferred embodiments of the invention.

EXAMPLE 1 Preparation of E-Caprolactone-TEPA Adduct

About 189 g (1.0 mole) of tetraethylene pentamine (TEPA) were mixed with 229 g (2.0 mole) of E-caprolactone (CL) and 0.25 ml of stannous octanoate (Sn(OCT)₂). The mixture was heated slowly to 140° C. and was kept at that temperature for two hours while stirring under a nitrogen blanket. Infrared analysis of the resulting product showed complete opening of lactone ring. The resulting product analyzed for 15.18% nitrogen.

EXAMPLES 2 & 3 Preparation of Polyisobutenyl Succinic Anhydride/E-Caprolactone-Polyamine Adduct Dispersants Part A

A polyisobutenyl succinic anhydride (PIBSA) having an SA:PIB ratio of 1.33 succinic anhydride (SA) moieties per polyisobutylene (PIB) molecule of about 1320 M_(n) was prepared by heating a mixture of 100 parts of polyisobutylene with 13 parts of maleic anhydride to a temperature of about 220° C. When the temperature reached 120° C., chlorine addition was begun and 10.5 parts of chlorine at a constant rate was added to the hot mixture for about 5 hours. The reaction was then heat soaked at 220° C. for about 1.5 hours and then stripped with nitrogen for about 1 hour. The resulting polyisobutenyl succinic anhydride had as ASTM Saponification Nuumber (SAP) of 103 which calculates to a succinic anhydride (SA) to polyisobutylene (PIB) ratio of 1.33 based upon the starting PIB as follows: ##EQU1##

The PIBSA product was 90 wt.% active ingredient (a.i.), the remainder being primarily unreacted PIB. The SA:PIB ratio of 1.33 is based upon the total PIB charged to the reactor as starting material, i.e., both the PIB which reacts and the PIB which remains unreacted.

Part B

The PIBSA of Part A was reacted with the E-caprolactone-TEPA adducts of Example 1 as follows:

About 0.08 mole (108.7 g) of the PIBSA of Part A were mixed with 24.5 g (0.05 mole) of the E-caprolactone-TEPA adduct of Example 1 and with enought S150N lubricating oil (solvent neutral oil having a viscosity of about 150 SUS at 100° C.) to provide a 50% active ingredient final product. The reaction mixture was slowly heated to 170°-180° C. and kept at this temperature for two hours while nitrogen sparging. At the end of the second hour, the oil diluted product was filtered and collected. It analyzed for 1.60% N.

EXAMPLE 3

The procedure of Example 2 was followed, except that 100 g (0.092 mole) of the PIBSA were reacted with 21 g (0.046 mole) of the caprolactone-TEPA adduct in the presence of mineral oil S150N to produce a 50% active ingredient oil solution. The resulting product analyzed for 1.30% nitrogen.

EXAMPLE 4 Preparation of E-Caprolactone PAM Adduct

The procedure of Example 1 was followed, except that about 139 g (1.0 mole) of polyamine bottoms (PAM) were substituted for the 189 g (1.0 mole) of TEPA.

EXAMPLES 5 Preparation of Polyisobutenyl Succinic Anhydride/E-Caprolactone-Pam Adduct Dispersant

To the reaction mixture formed in Example 4, there were added 1.5 mole (1630.5 g) of the PIBSA prepared in accordance with Example 2, Part A and sufficient S150N mineral oil to produce a 50% active ingredient oil solution. The reaction mixture was then heated to 170° C. for four hours while stirring under nitrogen sparging. The resulting product analyzed for 1.57% N.

EXAMPLE 6

The procedure of Example 5 was followed, except that 2.0 mole of the PIBSA were reacted with 1.0 mole of the caprolactone-PAM adduct. The product, which was diluted in S150N mineral oil to produce a 50% active ingredient solution, analyzed for 1.27% N.

Samples of a PIBSA-PAM dispersant (control) and the various PIBSA/caprolactone-polyamine adduct products of Examples 2, 3, 5, and 6 were then subjected to a standard sludge inhibition bench test (SIB) and a standard varnish inhibition bench test (VIB).

The SIB and VIB tests forecast the performance of a lubricant in a gasoline engine. These tests are described below. The SIB test employs a used crankcase mineral lubricating oil composition having an original viscosity of about 325 SUS at 37.8° C. that have been used in a taxicab that was driven generally for short trips only, thereby causing a buildup of a high concentration of sludge precursors. The oil used contains only a refined base mineral oil, a viscosity index improver, a pour point depressant and zinc dialkyl-dithiophosphate antiwear additives. The oil contains no sludge dispersants. Such oil is acquired by draining and refilling taxicab crankcases at about 1000-2000 mile intervals.

The SIB test is conducted in the following manner: The used crankcase oil is freed of sludge by centrifuging for one half hour at about 39,000 gravitives (gs). The resulting clear bright red oil is then decanted from the insoluble particles. However, the supernatant oil still contains oil-soluble sludge precursors which, under the conditions employed by this test, tend to form additional oil-insoluble deposits of sludge. The sludge inhibiting properties of the additives being tested are determined by adding to portions of the used oil 0.5 wt.% on an active basis, of the particular additive being tested. Ten grams of each one being tested is placed in a stainless steel centrifuge tube and is heated at 140° C. for 16 hours in the presence of air. Following the heating, the tube containing the oil being tested is cooled and then centrifuged for 30 minutes at about 39,000 gs. Any deposits of new sludge that form in this step are separated from the decanting supernatant oil and then carefully washed with 15 ml. of pentane to remove all remaining oils from the sludge. The weight, in milligrams, of the new solid sludge that forms in the test is determined by drying the residue and weighing it. The results are reported as milligrams of sludge per ten grams of oil thus measuring differences as small as one part per ten thousand. The less new sludge formed, the more effective is the additive as a dispersant. In other words, if the additive is effective, it will hold at least a portion of the new sludge that forms on heating and oxidation, stably suspended in the oil so that it does not precipitate down during the centrifuging period.

In the VIB test, a test sample consisting of ten grams of lubricating oil containing 0.5 wt.%, on an active basis, of the additive being evaluated is used. The test oil is a commercial lubricating oil obtained from a taxi after about 2000 miles of driving with said lubricating oil. Each sample is heat soaked overnight at about 140° C. and thereafter centrifuged to remove the sludge. The supernatant fluid of each sample is subjected to heat cycling from about 150° C. to room temperature over a period of 3.5 hours at a frequency of about two cycles per minute. During the heating phase, a gas containing a mixture of 0.7 volume percent SO₂, 1.4 volume percent NO and the balance air is bubbled through the test samples and during the cooling phase, water vapor was bubbled through the test samples. At the end of the test period, which testing cycle can be repeated as necessary to determine the inhibiting effect of any additive, the wall surfaces of the test flasks in which the samples are contained are visually evaluated as to the varnish inhibition. The amount of varnish deposited on the walls is rated at values of from one to eleven with the higher number being the greater amount of varnish. It has been found that this test forecasts the varnish results obtained as a consequence of carrying out the ASTM MS-VD engine tests which is described more fully hereinbelow.

Table I, which follows, summarizes the compositions tested and the test results:

                                      TABLE I                                      __________________________________________________________________________     Example                                                                             SA:PIB.sup.1                                                                        PIB M.sub.n.sup.2                                                                   SAP.sup.3                                                                          CL-AMINE/PIBSA.sup.4                                                                      AMINE.sup.5                                                                         Wt., % N                                                                            SIB.sup.6                                                                         VIB.sup.7                                                                         Haze                                                                              Viscosity, 100°,                                                        cs                            __________________________________________________________________________     Control            0          PAM  1.46 4.71                                                                              5  11 448.1                         2    1.33 1320 103 1:1.5      TEPA 1.60 3.23                                                                              3  11 387.4                         3    1.33 1320 103 1:2        TEPA 1.30 1.42                                                                              3  8  490.4                         5    1.33 1320 103 1:1.5      PAM  1.57 2.80                                                                              3  18 693                           6    1.33 1320 103 1:2        PAM  1.27 1.69                                                                              3  19 731                           __________________________________________________________________________      .sup.1 ratio of succinic anhydride moieties (SA) per polyisobutylene (PIB      molecule                                                                       .sup.2 number average molecular weight of PIB molecule                         .sup.3 ASTM saponification number                                              .sup.4 mole ratio of caprolactonepolyamine adduct (CLAMINE)                    polyisobutylene succinic anhydride (PIBSA) moieties                            .sup.5 identity of the polyamine used in the preparation of the dispersan      .sup.6 sludge inhibition bench test rating in milligrams sludge per 10         milligrams oil                                                                 .sup.7 varnish inhibition bench test rating on basis of 1 toll; the highe      the rating, the greater the amount of varnish deposited                  

The data in Table I indicate that the dispersants prepared by reacting PIBSA with the caprolactone-PAM and caprolactone-TEPA adducts have nitrogen levels similar to that of the control (PIBSA-PAM) when diluted to 50% with S150N oil. The data also indicate that the haze levels of the present dispersants are low, which is a desirable characteristic for a dispersant, and that the viscosities, while moderately higher than that of the control, are acceptable.

The SIB and VIB values for the present dispersants are exceptional when compared with those for the control. In fact, the values for both the SIB and VIB tests are considerably improved thus suggesting that the PIBSA/lactone-polyamine adducts of the invention are likely to outperform the known PIBSA-PAM type dispersants of corresponding SA:PIB, PIB M_(n) and % N values.

EXAMPLE 7 Preparation of E-caprolactone-PE adduct

About 136 g (1 mole) of PE(pentaerythritol) and 136.8 g (1.2 mole) of E-caprolactone were mixed with 0.1 g of Sn(OCT)₂ and heated slowly to 150° C. At about 130°-140° C. the reaction mixture became homogeneous. The mixture was stirred at 150° C. for one hour. The infrared analysis of the product showed complete reaction of the caprolactone. The product was poured into a large excess of methanol and no unreacted PE precipitated out of solution. The methanol was stripped off and the residue was collected. The product became a waxy solid upon standing at room temperature.

EXAMPLE 8 Preparation of Polyisobutenyl Succinic Anhydride/E-caprolactone-Polyol Adduct Dispersant

About 160 g (0.1 mole) of PIBSA prepared in accordance with Example 2, Part A and containing 59% active ingredient in S150N lubricating oil were combined with 84 g of S150N oil and 33 g (approximately 0.12 mole) of the caprolactone-PE adduct prepared in accordance with Example 7. The oil mixture was heated to 180° C. for four hours while sparging with nitrogen. The reaction was followed by infrared analysis and the resulting product was filtered and collected.

EXAMPLE 9 Preparation of Polyisobutenyl Succinic Anhydride-Polyol-Caprolactone Dispersant

About 160 g (0.1 mole) of PIBSA prepared in accordance with Example 2, Part A and containing 69% active ingredient in S105N lubricating oil were mixed with 14.5 g (0.12 mole) PE, 17.1 g (0.14 mole) of E-caprolactone, 82 g of S150N oil and 0.1 g Sn (OCT)₂. The oil mixture was slowly heated to 190° C. while sparging with nitrogen. The reaction mixture was then heated at 180° C. for four hours, while stirring and nitrogen stripping. The reaction was followed by infrared analysis and the resulting product was filtered and collected.

Samples of the products prepared in accordance with Examples 8 and 9, and a sample of a PIBSA-PE dispersant (control) were subjected to SIB and VIB tests as outlined above. Table II, which follows, summarized the compositions tested and the test results:

                                      TABLE II                                     __________________________________________________________________________                                PE/CL/        Viscosity                             Example                                                                             SA:PIB                                                                              PIB M.sub.n                                                                         SAP                                                                               CL-PE/PIBSA.sup.9                                                                       PIBSA.sup.10                                                                        SIB                                                                               VIB                                                                               Haze                                                                              100° C.,                       __________________________________________________________________________                                              cs                                    Control           0        0    3.31                                                                              3  38 597                                   8    1.33 1320 103                                                                               1:1      0    2.94                                                                              3  13 420                                   9    1.33 1320 103                                                                               0        1:1:1                                                                               1.56                                                                              3  35 9250                                  __________________________________________________________________________      .sup.9 mole ratio of caprolactonepentaerythritol adduct to polyisobutylen      succinic anhydride                                                             .sup.10 mole ratio of caprolactone to pentaerythritol to polyisobutylene       succinic anhydride                                                       

The data in Table II indicate that the dispersant prepared in accordance with the invention (Example 8) has a lower haze value than both a control PIBSA-PE dispersant of corresponding SA:PIB and PIB M_(n) and a similar PIBSA-CL-PE dispersant prepared by simultaneously reacting the PIBSA, CL and PE (Example 9). The data also indicate that the SIB and VIB test values of the dispersant of this invention compare quite favorably with the PIBSA-PE and PIBSA-CL-PE dispersants.

EXAMPLES 10-13 Preparation of PIBSA-PE Dispersants

Four PIBSA-PE dispersants were prepared by mixing PIBSA, PE and S105N lubricating oil in a reaction flask and heating the mixture to 200°-210° C. in the presence of an alkyl sulfonic acid catalyst while stirring under a nitrogen blanket. Each reaction mixture was kept at this temperature until complete esterification was obtained. The resulting oil solutions of PIBSA-PE were filtered and collected. Samples of the PIBSA-PE products were then subjected to SIB and VIB tests. The compositions tested and the test results appear below in Table III.

EXAMPLES 14-17 Preparation of PIBSA-PE/CL Dispersants

Four PIBSA-PE/CL dispersants were prepared by reacting caprolactone with PIBSA-PE dispersant prepared in accordance with Examples 10-14. In each example, the PIBSA-PE, caprolactone and about 0.1 g Sn(OCT)₂, based on the weight of the PIBSA, were slowly heated to about 160° C. while stirring under a nitrogen blanket. The mixture was kept at 160° C. for about three hours and the resulting PIBSA-PE/CL product was nitrogen stripped at 160° C. for about ten minutes and collected. Samples of the five PIBSA-PE/CL products were then subjected to SIB and VIB tests. The compositions tested and the test results appear below in Table III.

EXAMPLES 18-21 Preparation of PIBSA/Caprolactone-PE Adduct Dispersants

Four PIBSA/caprolactone-PE adduct dispersants were prepared in accordance with the procedure outlined in outlined in Example 8. Samples of the dispersants were then subjected to SIB and VIB tests. The compositions tested and the test results appear in Table III, which follows.

    TABLE III            PIBSA PE PE-CL.sup.12 CL             PIBSA g g g g Oil CL/PIBSA      SA117.sup.13   Viscosity Example SA:PIB PIB M.sub.n SAP ai.sup.11 (m)      (m) (m) (m) g m/m g Sn(OCT).sub.2 Haze 100°       C., cs SIB VIB          10 1.14 1300 90.4 90.5 200 23.94 0 0 194 g 0      1.9 0 22 593 1.48 2      (.16) (.18) 14 1.14 1300 90.4 90.5 200 23.94 0      5.5 200 .31 1.9 .2 19 610 2.05 2      (.16) (.18)  (.05) 18 1.14 1300      90.4 90.5 200 0 45 0 204 1 0 0 12 487 1.31 3      (.16)  (.18) 11 1.12      1700 69.3 85.2 200 18.51 0 0 157.9 0 1.8 0 35 1176 2.27 2      (.12)      (.14) 15 1.12 1700 69.3 85.2 200 18.51 0 4.21 162 .31 1.8 .2 32 1102      0.68 2      (.12) (.14)  (.04) 19 1.12 1700 69.3 85.2 200 0 35 0 174 1 0      0 59 721 2.22 3      (.12)  (.14) 12 1.06 1900 59.5 82.2 200 16.5 0 0      143 0 1.7 0 29 1485 .77 2      (.11) (.12) 16 1.06 1900 59.5 82.2 200      16.5 0 3.9 147 .31 1.7 .2 20 1614 4.03 2     (.11) (.12)  (.03) 20 1.06      1900 59.5 82.2 200 0 30 0 156 1 0 0 27 1095 1.48 3.5      (.11) 13 1.10      2250 52.2 78.9 200 13.6 0 0 128 0 1.6 0 32 1411 3.32 2      (.09) (.10)      17 1.10 2250 52.2 78.9 200 13.6 0 3.2 131 .31 1.6 .2 36 1662 3.32 2      (.09) (.10)  (.03) 21 1.10 2250 52.2 78.9 200 0 25 0 139 1 0 0 37 949      1.58 3.5      (.09)      .sup.11 weight % active ingredient      .sup.12 caprolactonepentaerythritol adduct      .sup.13 alkyl sulfonic acid esterification catalyst

The data in Table III indicate that the dispersant viscosities are significantly lower for the dispersants prepared in accordance with the present invention by reacting PIBSA with a caprolactone-PE adduct (Examples 18-21), when compared to dispersants of a generally corresponding PIBSA when the PIBSA is reacted only with PE (Examples 10-13) or when PIBSA is reacted first with PE and then is capped with caprolactone (Examples 14-17). The data also indicate that the SIB and VIB test values of the dispersants prepared in accordance with the invention (Examples 18-21) compare favorably with the generally correspond PIBSA type dispersants prepared by the alternative routes.

EXAMPLE 22 Preparation of E-Caprolactone THAM Adduct

About 1210 g (1.0 mole) of 2-amino-2-(hydroxymethyl)-1,3-prepanediol (THAM) was combined with 1140 g (1.0 mole) of E-Caprolactone and 0.1 g Sn(OCT)₂. The reaction mixture was slowly heated to 150° C. under a nitrogen blanket. After one-half hour at 150° C., a clear solution was obtained. The Infrared analysis of the reaction product showed no unreacted caprolactone. Upon heating the product cyclilized to a hydroxy-oxazoline, and a strong absorption band at 6.0 microns the infrared spectrum was observed. The product analyzed for 50.94% C, 9.29% H and 5.79% N.

EXAMPLE 23 Preparation of Polyisobutenyl Succinic Anhydride/E-caprolactone-THAM Adduct

About 80 g (0.05 mole) of a 69% ai PIBSA prepared in accordance with Example 2, Part A was mixed with 0.1 mole of the caprolactone-THAM adduct of Example 22, and the mixture was heated to 180° C. while nitrogen sparging for three hours. Infrared analysis of the resulting oil solution showed strong ester-oxazoline absorption bands. The resulting PIBSA-Bis(ester-oxazoline) product analyzed for 0.85%N.

EXAMPLE 24 Preparation of Polyisobutenyl Succinic Anhydride-THAM Dispersant

The procedure of Example 23 was repeated except that 0.1 mole of THAM was used in place of the caprolactone-THAM adduct. The resulting product was a PIBSA-Bisoxazoline.

Samples of the PIBSA-Bis(ester-oxazoline) of Example 23 and the PIBSA-Bisoxazoline of Example 24 were subjected to the standard SIB and VIB test and to a storage stability test. The storage stability test involved placing samples of the dispersants in a forced air oven in the presence of air at a temperature of 100° C. for a period of 338 hours and determining the percentage of oxazoline in the samples at various time during the test period.

Tables IV and V, which follow, summarize the compositions tested and the test results:

                                      TABLE IV                                     __________________________________________________________________________                       PIBSA                                                                              THAM                                                                               CL-THAM                                              Example                                                                             SA:PIB                                                                              PIB M.sub.n                                                                         SAP                                                                               m   m   m     CL-PIBSA                                                                             SIB                                                                               VIB                                   __________________________________________________________________________     23   1.33 1320 103                                                                               .05 0   .1    2     5.95                                                                              3                                     24   1.33 1320 103                                                                               .05 .1  0     2     5.72                                                                              5                                     __________________________________________________________________________

                  TABLE V                                                          ______________________________________                                         Time,                                                                          Hr.   % Oxazoline (Example 24)                                                                         % Oxazoline (Example 23)                               ______________________________________                                         0     78.64             90.18                                                  127   71.67             90.60                                                  169   69.80             92.43                                                  265   64.44             88.62                                                  388   61.33             85.13                                                  ______________________________________                                    

The data in Tables IV and V indicate that the dispersant prepared by reacting PIBSA with the caprolactone-THAM adduct (Example 23) showed considerably improved VIB test results over the control dispersant (Example 24) which has no caprolactone-derived units. The data also indicate that the decrease in % oxazoline over the test period of 338 hours was about 17% for the control sample, but only about 5% for the PIBSA/Caprolactone-THAM sample. This latter result clearly demonstrates the stabilizing effect of incorporating caprolactone as an adduct with THAM prior to reacting the THAM with PIBSA.

As will be evident to those skilled in the art, various modifications on this invention can be made or followed, in light of the foregoing disclosure and illustrative examples, tables and discussion, without departing from the spirit and scope of the disclosure or from the scope of the invention as set forth in the following claims. 

What is claimed is:
 1. A C₅ -C₉ lactone adduct material useful as an oil additive and formed by reacting at a temperature of from about 100° to about 250° C. and for a period of from about 1 to about 10 hours a hydrocarbyl substituted C₄ -C₁₀ dicarboxylic acid producing material (I) with the reaction product (II) of a C₅ -C₉ lactone with a member selected from the group consisting of (a) a polyamine having from about 2 to 60 total carbon atoms and from about 2 to about 12 nitrogen atoms, (b) an aliphatic polyhydric alcohol containing up to about 100 carbon atoms and from about 2 to about 10 hydroxyl groups, (c) an amino alcohol containing up to about 50 total carbon atoms, from 1 to about 3 nitrogen atoms and from 1 to about 15 hydroxyl group, and (d) mixtures thereof, said reaction product (II) being prepared at a temperature of from about 30° to about 200° C. When said C₅ -C₉ lactone is reacted with said polyamine and at a temperature of from about 50° to about 200° C. when said C₅ -C₉ lactone is reacted with said aliphatic polyhydric alcohol or with said amino alcohol, said hydrocarbyl substituted acid producing material being formed by reacting an olefin polymer of a C₂ -C₁₀ monoolefin having a number average molecular weight of about 300 to about 10,000 and a C₄ -C₁₀ monosaturated dicarboxylic acid material selected from the group consisting of acids, esters and anhydrides, and containing an average of from about 0.7 to about 2.0 moles of dicarboxylic acid producing material per mole of said olefin polymer used in the reaction, said adduct having, on the average, a degree of polymerization of C₅ -C₉ lactone of less than about
 100. 2. The C₅ -C₉ lactone adduct material of claim 1, wherein said olefin polymer is polyisobutylene.
 3. The C₅ -C₉ lactone adduct material of claim 2, wherein said lactone is E-caprolactone.
 4. The C₅ -C₉ lactone adduct material of claim 3, wherein said C₄ -C₁₀ monounsaturated dicarboxylic acid material is maleic anhydride.
 5. The C₅ -C₉ lactone adduct material of claim 4, wherein there are about 1 to about 1.5 succinic anhydride units per polyisobutenyl moiety present in said hydrocarbyl substituted C₄ -C₁₀ dicarboxylic acid producing material and wherein the number average molecular weight of said polyisobutylene is from about 500 to about 3,000.
 6. The C₅ -C₉ lactone adduct material of claim 1, wherein said C₅ -C₉ lactone is reacted with a polyamine, and wherein said polyamine is an aliphatic saturated amine having the formula: ##STR13## wherein R and R' independently are selected from the group consisting of hydrogen, C₁ to C₂₅ straight or branched chain alkyl radicals, C₁ to C₁₂ alkoxy C₂ to C₆ alkylene radicals, and C₁ to C₁₂ alkylamino C₂ to C₆ alkylene radicals; each s is the same or a different number of from 2 to 6; and t is a number of from 0 to 10, with the provision that when t=0; at least one of R or R' must be H such that there are at least two of either primary or secondary amino groups.
 7. The C₅ -C₉ lactone adduct material of claim 6, wherein said amine is selected from the group consisting of 1,2-diaminoethane, 1,3-diaminopropane, 1,4-diaminobutane, 1,6-diaminohexane, diethylene triamine, triethylene tetramine, tetraethylene pentamine, 1,2-propylene diamine, di-(1,2-propylene)triamine, di-(1,3-propylene)triamine, N,N-dimethyl-1,3-diaminopropane, N,N-di-(2-aminoethyl)ethylene diamine, and N-dodecyl-1,3-propane diamine.
 8. The C₅ -C₉ lactone adduct material of claim 1, wherein said amine is selected from the group consisting of alicyclic diamines, imidazolines, morpholines, and N-aminoalkyl piperazines of the general formula: ##STR14## wherein G is independently selected from the group consisting of hydrogen and omega(nontertiary)-aminoalkylene radicals of from 1 to 3 carbon atoms, and p is a number of from 1 to
 4. 9. The C₅ -C₉ lactone adduct material of claim 1, wherein said amine is a mixture of poly(ethyleneamines) averaging about 5 to about 7 nitrogen atoms per molecule.
 10. The C₅ -C₉ lactone adduct material of claim 1, wherein said amine is a polyoxyalkylene polyamine having the formula:

    NH.sub.2 -alkylene-(O-alkylene).sub.m -NH.sub.2

wherein m has a value of about 3 to 70: or

    R-[alkylene-(O-alkylene).sub.n -NH.sub.2 ].sub.a

wherein n has a value of about 1 to 40 with the provision that the sum of all the n's is from about 3 to about 70, R is a substituted saturated hydrocarbon radical of up to 10 carbon atoms, wherein the number of substituents on the R group is represented by the value of "a", which is a number from 3 to
 6. 11. The C₅ -C₉ lactone adduct material of claim 5, wherein said C₅ -C₉ lactone is reacted with a polyamine, and wherein said polyamine is an aliphatic saturated amine having the formula: ##STR15## wherein R and R' independently are selected from the group consisting of hydrogen, C₁ to C₂₅ straight or branched chain alkyl radicals, C₁ to C₁₂ alkoxy C₂ to C₆ alkylene radicals, and C₁ to C₁₂ alkylamino C₂ to C₆ alkylene radicals; each s is the same or a different number of from 2 to 6; and t is a number of from 0 to 10, with the provision that when t=0, at least one of R or R' must be H such that there are at least two of either primary or secondary amino groups.
 12. The C₅ -C₉ lactone adduct material of claim 11, wherein said amine is selected from the group consisting of 1,2-diaminoethane, 1,3-diaminopropane, 1,4-diaminobutane, 1,6-diaminohexane, diethylene triamine, triethylene tetramine, tetraethylene pentamine, 1,2-propylene diamine, di-(1,2-propylene)triamine, di-(1,3-propylene)triamine, N,N-dimethyl-1,3-diaminopropane, N,N-di-(2-aminoethyl)ethylene diamine, and N-dodecyl-1,3-propane diamine.
 13. The C₅ -C₉ lactone adduct material of claim 5, wherein said amine is selected from the group consisting of alicyclic diamines, imidazolines, morpholines, and N-aminoalkyl piperazines of the general formula: ##STR16## wherein G is independently selected from the group consisting of hydrogen and omega-(nontertiary)aminoalkylene radicals of from 1 to 3 carbon atoms, and p is a number of from 1 to
 4. 14. The C₅ -C₉ lactone adduct material of claim 5, wherein said amine is a mixture of poly (ethyleneamines) averaging about 5 to about 7 nitrogen atoms per molecule.
 15. The C₅ -C₉ lactone adduct material of claim 5, wherein said amine is a polyoxyalkylene polyamine having the formula:

    NH.sub.2 -alkylene-(O-alkylene).sub.m -NH.sub.2

wherein m has a value of about 3 to 70: or

    R-[alkylene-(O-alkylene).sub.n -NH.sub.2 ].sub.a

wherein n has a value of about 1 to 40 with the provisions that the sum of all the n's is from about 3 to about 60, R is a substituted saturated hydrocarbon radical of up to 10 carbon atoms, wherein the number of substituents on the R group is represented by the value of "a", which is a number from 3 to
 6. 16. The C₅ -C₉ lactone adduct material of claim 1, wherein said C₅ -C₉ lactone is reacted with a polyhydric alcohol.
 17. The C₅ -C₉ lactone adduct material of claim 16, wherein said polyhydric alcohol is an aliphatic alcohol containing from 3 to 15 carbon atoms and at least three hydroxyl groups.
 18. The C₅ -C₉ lactone adduct material of claim 17, wherein said polyhydric alcohol is a member selected from the group consisting of glycerol erythritol, pentaerythritol, mannitol, sorbitol, 1,2,4-hexanetriol and tetrahydroxy pentane.
 19. The C₅ -C₉ lactone adduct material of claim 5, wherein said C₅ -C₉ lactone is reacted with a polyhydric alcohol.
 20. The C₅ -C₉ lactone adduct material of claim 19, wherein said polyhydric alcohol is an aliphatic alcohol containing from 3 to 15 carbon atoms and at least three hydroxyl groups.
 21. The C₅ -C₉ lactone adduct material of claim 20, wherein said polyhydric alcohol is a member selected from the group consisting of glycerol, erythritol, pentaerythritol, mannitol, sorbitol, 1,2,4-hexanetriol and tetrahydroxy pentane.
 22. The C₅ -C₉ lactone adduct material of claim 1, wherein said C₅ -C₉ lactone is reacted with an amino alcohol.
 23. The C₅ -C₉ lactone adduct material of claim 22, wherein said amino alcohol is a 2,2-disubstituted-2-amino-1-alkanol of the formula ##STR17## wherein X is alkyl or hydroxyalkyl group with the alkyl groups having from 1 to 3 carbon atoms, wherein at least one of the X substituents is a hydroxyalkyl group of the formula ##STR18## and wherein n is 1 to
 3. 24. The C₅ -C₉ lactone adduct material of claim 23, wherein said amino alcohol is tris(hydroxymethyl)amino methane.
 25. The C₅ -C₉ lactone adduct material of claim 5, wherein said C₅ -C₉ lactone is reacted with an amino alcohol.
 26. The C₅ -C₉ lactone adduct material of claim 25, wherein said amino alcohol is a 2,2-disubstituted-2-amino-1-alkanol of the formula: ##STR19## wherein X is alkyl or hydroxyalkyl group with the alkyl groups having from 1 to 3 carbon atoms, wherein at least one of the X substituents is a hydroxyalkyl group of the formula (CH₂)_(n) OH, and wherein n is 1 to
 3. 27. The C₅ -C₉ lactone adduct material of claim 26, wherein said amino alcohol tris(hydroxymethyl)amino methane.
 28. An oil soluble dispersant useful as an oil additive, comprising the product of a reaction mixture comprising as reactants:(I) a hydrocarbyl substituted C₄ -C₁₀ monounsaturated dicarboxylic acid producing material formed by reacting olefin polymer of C₂ to C₁₀ monoolefin having a number average molecular weight of about 300 to 10,000 and a C₄ to C₁₀ monounsaturated acid material selected from the group consisting of acids, esters and anhydrides, said hydrocarbyl substituted C₄ -C₁₀ monounsaturated dicarboxylic acid producing material contains from about 0.7 to about 2.0 moles of dicarboxylic acid producing material per mole of said olefin polymer in the reaction mixture; and (II) a C₅ -C₉ lactone adduct formed by reacting (a) a C₅ -C₉ lactone with (b) a member selected from the group consisting of (i) a polyamine having from about 2 to 60 total carbon atoms and from about 2 to about 12 nitrogen atoms, (ii) an aliphatic polyhydric alcohol containing up to about 100 total carbon atoms and from about 2 to about 10 hydroxyl groups, (iii) an amino alcohol containing up to about 50 total carbon atoms, from 1 to about 3 nitrogen atoms and from 1 to about 15 hydroxyl groups, and (iv) mixtures of (i), (ii), and (iii), wherein there are from about 0.2 to about 50 molar equivalents of C₅ -C₉ lactone derived moieties per molar equivalent of said adduct (II) used in the reaction, said dispersant having been prepared by heating together reactants (I) and (II) at a temperature of from about 100° to about 250° C. for a period of from about 1 to about 10 hours.
 29. An oil soluble dispersant according to claim 28, wherein said C₅ -C₉ lactone is caprolactone.
 30. An oil soluble dispersant according to claim 29, wherein said caprolactone is reacted with a polyamine.
 31. An oil soluble dispersant according to claim 30, wherein said polyamine is an aliphatic saturated amine having the general formula ##STR20## wherein R and R' independently are selected from the group consisting of hydrogen: C₁ to C₂₅ straight of branched chain alkyl radicals, C₁ to C₁₂ alkoxy C₂ to C₆ alkylene radicals, and C₁ to C₁₂ alkylamino C₂ to C₆ alkylene radicals; each s is the same or a different number of from 2 to 6; and t is a number of from 0 to 10, with the provision that when t=0, at least one of R or R' must be H such that there are at least two of either primary of secondary amino groups.
 32. An oil soluble dispersant according to claim 31, wherein said polyamine is selected from the roup consisting of 1,2-diaminoethane: 1,3-diaminopropane; 1,4-diaminobutane; 1,6-diaminohexane; diethylene triamine; triethylene tetramine; tetraethylene pentamine; 1,2-propylene diamine; di-(1,2-propylene)triamine; di-(1,3-propylene)triamine; N,N-dimethyl-1,3-diaminopropane; N,N-di-(2-aminoethyl)ethylene diamine; and N-dodecyl-1,3-propane diamine.
 33. The oil soluble dispersant of claim 30, wherein said polyamine is selected from the group consisting of alicyclic diamines, imidazoles, morpholines, and N-aminoalkyl piperazines of the general formula: ##STR21## wherein G is independently selected from the group consisting of hydrogen and omega-(nontertiary)-aminoalkylene radicals of from 1 to 3 carbon atoms, and p is a number of from 1 to
 4. 34. The oil soluble dispersant of claim 30, wherein said polyamine is a mixture of poly(ethyleneamines) averaging about 5 to about 7 nitrogen atoms per molecule.
 35. An oil soluble dispersant according to claim 30, wherein said polyamine is a polyoxyalkylene polyamine having the formula: ##STR22## where m has a value of about 3 to 70; or ##STR23## wherein n has a value of about 1 to 40 with the provision that the sum of all the n's is from about 3 to about 70, R is a substituted saturated hydrocarbon radical of up to 10 carbon atoms, wherein the number of substituents on the R group is represented by the value of "a", which is a number from 3 to
 6. 36. An oil soluble dispersant according to claim 29, wherein said caprolactone is reacted with a polyhydric alcohol.
 37. An oil soluble dispersant according to claim 36, wherein said polyhydric alcohol is an aliphatic alcohol containing from 3 to 15 carbon atoms and at least three hydroxyl groups.
 38. An oil soluble dispersant according to claim 37, wherein said polyhydric alcohol is a member selected from the group consisting of glycerol, erythritol, pentaerythritol, mannitol, sorbitol, 1,2,4-hexanetriol and tetrahydroxy pentane.
 39. An oil soluble dispersant according to claim 29, wherein said caprolactone is reacted with an amino alcohol.
 40. An oil soluble dispersant according to claim 39, wherein said amino alcohol is a 2,2-disubstituted-2-amino-1-alkanol of the formula ##STR24## wherein X is a alkyl or hydroxyalkyl group with the alkyl groups having from 1 to 3 carbon atoms, wherein at least one of the X substituents is a hydroxyalkyl group of the formula ##STR25## and wherein n is 1 to
 3. 41. An oil soluble dispersant according to claim 40, wherein said amino alcohol is tris(hydroxymethyl)amino methane.
 42. An oil soluble reaction product useful as an oil additive, comprising:(a) polymer consisting essentially of C₂ to C₁₀ monoolefin, said polymer being of 300 to 10,000 number average molecular weight and being substituted with succinic moieties selected from the group consisting of acid, anhydride and ester groups, wherein there are about 0.7 to about 2.0 molar proportions of succinic moieties per molar proportion of said polymer, (b) amine containing 2 to 60 carbon atoms and 2 to 12 nitrogen groups, and, (c) C₅ -C₉ lactone, wherein (b) is first reacted with (c) at a temperature of from about 30° to about 200° C., wherein the resulting product is then reacted with (a) at a temperature of from about 100° to about 250° C. for a period of from about 1 to about 10 hours, and wherein there are from about 0.2 to about 100 molar proportions of (c) per molar proportion of said reaction product.
 43. The oil soluble reaction product according to claim 42 wherein (a) is polyisobutylene of about 500 to 3,000 number average molecular weight substituted with succinic anhydride moieties, wherein (c) is E-caprolactone, and wherein there are about 0.5 to 20 molar proportions of (c) per molar proportion of said reaction product.
 44. An oil soluble reaction product useful as an oil additive, comprising:(a) polymer consisting essentially of C₂ to C₁₀ monoolefin, said polymer being of 300 to 10,000 number average molecular weight and being substituted with succinic moieties selected from the group consisting of acid, anhydride and ester groups, wherein there are about 0.7 to about 2.0 molar proportions of succinic moieties per molar proportion of said polymer, (b) aliphatic polyhydric alcohol containing up to about 100 total carbon atoms and from 2 to about 10 hydroxyl groups, and (c) C₅ -C₉ lactone,wherein (b) is first reacted with (c) at a temperature of from about 50° to about 200° C., wherein the resulting product is then reacted with (a) at a temperature of from about 100° to about 250° C. for a period of from about 1 to about 10 hours, and wherein there are from about 0.2 to about 100 molar proportions of (c) per molar proportion of said reaction product.
 45. The oil soluble reaction product according to claim 44 wherein (a) is polyisobutylene of about 500 to 3,000 molecular weight substituted with succinic anhydride moieties, wherein (c) is E-caprolactone, and wherein there are about 0.5 to 20 molar proportions of (c) per molar proportion of said reaction product.
 46. An oil soluble reaction product useful as an oil additive, comprising:(a) polymer consisting essentially of C₂ to C₁₀ monoolefin, said polymer being of 300 to 10,000 number average molecular weight and being substituted with succinic moieties selected from the group consisting of acid, anhydride and ester groups wherein there are about 0.7 to about 2.0 molar proportions of succinic moieties per molar proportion of said polymer, (b) amino alcohol containing up to about 50 total carbon atoms, from 1 to about 3 nitrogen atoms and from 1 to about 15 hydroxyl groups, and (c) C₅ -C₉ lactone,wherein (b) is first reacted with (c) at a temperature of from about 50° to about 200° C., wherein the resulting product is then reacted with (a) at a temperature of from about 100° to about 250° C. for a period of from about 1 to about 10 hours, and wherein there are from about 0.2 to about 100 molar proportions of (c) per molar proportion of said reaction product.
 47. The oil soluble reaction product according to claim 46 wherein (a) is polyisobutylene of about 500 to 3,000 number average molecular weight substituted with succinic anhydride moieties, wherein (c) is E-caprolactone, and wherein there are about 0.5 to 20 molar proportions of (c) per molar proportion of said reaction product. 